NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZR 1.5, MZR 1.6]

id0103e0801100

5

ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION
•  The engine stops unexpectedly at idle and/or after start.
POSSIBLE CAUSE
•  Coil antenna connector is not connected securely
•  Instrument cluster or related wiring harness malfunction
•  Continuous memory DTC is stored
•  Improper operation of drive-by-wire control system
•  Air leakage from intake-air system
•  Electrical connector disconnection
•  Poor fuel quality
•  Fuse malfunction
•  Ignition wiring malfunction
•  Intake-air system restriction
•  Vacuum leakage
•  Improper operation of drive-by-wire control system
•  CKP sensor and related wiring harness malfunction
•  Spark plug malfunction
•  Improper operation of fuel injector
•  Improper operation of fuel pump
•  Inadequate fuel pressure
•  EVAP control system malfunction
•  Improper operation of EGR control system (with EGR system)
•  Improper operation of A/C system
•  Restriction in exhaust system
•  Improper operation of variable valve timing control system
•  Low engine compression
•  PCV valve malfunction
•  Valve timing malfunction
•  PCM malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
•  Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 1.5, MZR 1.6].) (See AFTER SERVICE PRECAUTION [MZR 1.5, MZR 1.6].)
Caution
•  Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure

STEP

INSPECTION

ACTION
1
Perform the DTC Reading Procedure.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.5, MZR 1.6].)
If the engine stalls:
•  Perform the KOEO self test.
If the engine does not stall:
•  Perform the KOEO or KOER self test.
Are any continuous memory DTCs present?
Yes
DTC is displayed:
•  Go to the appropriate DTC inspection.
Communication error message is displayed:
•  Inspect the following:
―  Open circuit in wiring harness between main relay terminal B and PCM terminal 1AJ
―  Open circuit in wiring harness between main relay terminal C and PCM terminal 1BB, 1BE and 1BF
―  Main relay is stuck open
―  Open or short circuit in wiring harness between DLC-2 and PCM terminals 1AE and 1AI
―  Open or poor PCM ground circuit
―  Poor connection of vehicle body ground
•  Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
2
Inspect the following:
•  Air leakage from intake-air system
•  Electrical connections
•  Fuel quality (proper octane, contamination, winter/summer blend)
•  Fuses
•  Ignition wiring
•  Intake-air system restriction (such as air cleaner element, fresh air duct)
•  Proper sealing of intake manifold and components attached to intake manifold: EGR valve (with EGR system)
•  Vacuum connection
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 1.
No
Go to the next step.
3
Attempt to start the engine at part throttle.
Does the engine run smoothly at part throttle?
Yes
Perform the Drive-by-wire Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
4
Access the RPM PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.5, MZR 1.6].)
Is the RPM PID value indicating the engine speed during engine cranking?
Yes
Go to the next step.
No
Inspect the CKP sensor and related wiring harness.
(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR 1.5, MZR 1.6].)
•  If there is a malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction:
―  Go to the next step.
5
Perform the Spark Test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Is the strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
6
Perform the Fuel Injector Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
7
Perform the Fuel Pump Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
8
Inspect the fuel line pressure.
(See FUEL LINE PRESSURE INSPECTION [MZR 1.5, MZR 1.6].)
Is the fuel line pressure correct?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
9
Inspect the EVAP control system.
(See PURGE SOLENOID VALVE INSPECTION [MZR 1.5, MZR 1.6].)
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
With EGR system:
•  Go to the next step.
Without EGR system:
•  Go to Step 11.
10
Perform the EGR Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
11
Note
•  Following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
Inspect the refrigerant pressure.
(See REFRIGERANT PRESSURE CHECK.)
Are the pressures within specifications?
Yes
Go to the next step.
No
If the A/C is always on:
•  Go to the symptom troubleshooting “NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY”.
For other symptoms:
•  Inspect the following:
―  Refrigerant charging amount
―  Condenser fan operation
•  Repair or replace the malfunctioning part according to the inspection results.
12
Visually inspect the exhaust system part.
Is there any deformed exhaust system part?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
13
Perform the Variable Valve Timing Control System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.5, MZR 1.6].)
Does the variable valve timing control system operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
14
Inspect the engine compression.
(See COMPRESSION INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Inspect for cause.
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
15
Inspect the PCV valve operation.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 1.5, MZR 1.6].)
Is there any malfunction?
Yes
Replace the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)
No
Inspect the valve timing.
Repair or replace malfunctioning part according to inspection results.
16
Verify the test results.
•  If normal, return to diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR 1.5, MZR 1.6].)
•  If malfunction remains, inspect related Service information perform repair or diagnosis.
―  If vehicle repaired, troubleshooting completed.
―  If vehicle not repaired or additional diagnostic information not available, replace the PCM. (See PCM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)